2002–2007 Suzuki Eiger 400 LT-A400/400F Service & Repair Manual (P/N 99500-43045-01E)

• Model and document coverage: Covers the 2002 LT-A400K2 and LT-A400FK2 base models and the K3 through K7 updates for 2003-2007 Suzuki Eiger 400 ATVs: LT-A400 2WD and LT-A400F selectable 2WD/4WD. This 424-page PDF reproduces the Suzuki factory service manual, and the cover carries Suzuki number 99500-43045-01E.
• Engine and automatic-drivetrain repair: Includes engine removal and installation, top- and bottom-end disassembly, cylinder-head and valve service, piston and crankshaft inspection, oil-pump work, recoil-starter repair, clutch and V-belt service, transfer teardown, and engine reassembly.
• Front and rear drive service: Details LT-A400F front differential removal, disassembly, bearing and seal inspection, 2WD/4WD shifting components, reassembly, shim selection, backlash and tooth-contact checks, plus equivalent rear final-drive repair procedures.
• Chassis and brake procedures: Covers LT-A400F front drive shafts, wheel hubs, twin front disc brakes, master cylinder and calipers, rear drum brake, brake-fluid replacement and bleeding, front and rear suspension, steering, toe-in adjustment, swingarm, and rear axle service.
• Fuel, oil-cooling, and electrical diagnosis: Provides Keihin carburetor overhaul, fuel-valve and level-gauge service, SACS oil-cooling and lubrication checks, cooling-fan and switch testing, and fault isolation for charging, starting, ignition, lighting, switches, and battery systems.
• Factory reference material: Supplies the periodic-maintenance chart, system troubleshooting tables, exploded assembly views, wiring and routing diagrams, special-tool listings, tightening-torque tables, fluid specifications, wear limits, clearances, and electrical test data.

The mechanical coverage is specific to the 376 cc single-cylinder, four-stroke OHC engine with Suzuki's SACS oil-cooling system, a Keihin CVK32 carburetor, wet-shoe automatic centrifugal clutch, automatic V-belt transmission, and hand-operated L-H-N-R transfer. Suzuki wrote this manual for mechanics who already have the service knowledge, workshop equipment, and special tools the procedures call for; it is not an introductory repair course.

Model-Year Organization

The main service chapters are based on the 2002 K2 machines. Each later chapter documents only what changed, so K3-K7 work must be read together with the applicable earlier material rather than treated as a separate stand-alone manual. The 2003 supplement is divided into K3-I and K3-II coverage, adding revised specifications and service data, transfer and gearshift-cam work, chassis reassembly information, a wiring diagram, and cable routing. The K4 section adds front propeller-shaft flange-coupling information plus revised wiring, harness, and cable routing. K5 and K6 concentrate on changed torque and service data, including the K5 front-caliper fastener treatment. The K7 section is limited to revised front-brake-hose routing and states that K6 specifications and service data still apply.

Repair Depth and Shop Data

The engine chapter separates parts that can be serviced in the frame from work that requires engine removal. Inspection coverage reaches the camshaft, cam-chain tensioner, cylinder head, valves and guides, piston, connecting rod, crankshaft, clutch, movable drive and driven faces, belt, transfer, shift fork, gearshift cam, and internal bevel-drive components. The front differential and rear final-drive chapters go beyond removal and replacement: they include bearing and seal work, shim selection, gear backlash, and tooth-contact evaluation during reassembly.

Troubleshooting tables connect symptoms to likely causes across the engine, drivetrain, carburetor, chassis, brakes, electrical system, and battery. The electrical chapter adds charging-, starter-, and ignition-system diagnostic charts, component tests, starter-motor overhaul, and multimeter procedures. Service data is organized by assembly and includes factory inspection limits, adjustment ranges, torque specifications, approved lubricants, capacities, and model-year changes without forcing the reader to piece values together from a generic specification sheet.

Diagrams and Special Tools

Named visual references include the cylinder-head cooling-system chart, engine lubrication-system chart, K2/K3/K4 wiring diagrams, wiring-harness routing views, carburetor-hose routing, and front-brake-hose routing, including the K7 revision. Exploded views identify component placement, lubrication points, locking-agent locations, and fasteners throughout the repair chapters.

The special-tool index provides names and Suzuki numbers, including the crankshaft installer 09910-32812, crankcase separating tool 09920-13120, movable-driven-face spring compressor 09922-31430, drive-shaft remover 09924-21930, multi-circuit tester set 09900-25008, and oil-pressure gauge 09915-74511.

The repair cautions are component-specific. The manual warns that driving the crankshaft into the crankcase can disturb crankshaft alignment, while applying compressed air to the carburetor before removing its diaphragm can damage the diaphragm. Engine removal, driven-face spring work, brake service, and fuel-system repair require the specified workshop equipment and the manual's safety procedures before work begins.